HEAT PUMP DRYER INCLUDING A HEAT EXCHANGER BYPASS SYSTEM

Abstract

A laundry appliance includes a cabinet. A drum is supported in the cabinet. A blower fan is configured to generate an airflow. A basement is arranged in the cabinet. The basement includes a basement inlet connected to the blower fan and a basement outlet connected to the drum. A heat exchanger system is arranged in the basement. A bypass duct is arranged in the cabinet. The bypass duct includes a bypass inlet in fluid communication with the blower fan and a bypass outlet in fluid communication with the drum. A control module is configured to connect the blower fan with the bypass inlet of the bypass duct and isolate the heat exchanger system from the airflow during a first portion of a drying cycle and connect the basement inlet with the blower fan to direct the airflow across the heat exchanger system during a second portion of the drying cycle.

Description

FIELD

The present disclosure relates to the art of laundry appliances and, more particularly, to a heat pump dryer including a heat exchanger bypass system.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Laundry appliances are prolific in both residential and commercial settings. The laundry appliance may be a dryer machine that is used to dry laundry after it has been cleaned in a washing machine. In some examples, the laundry appliance may be a washer and dryer combination appliance where a single machine performs both the washing and drying functions. There are a number of different names used to describe washer and dryer combination appliances, including without limitation, “washer/dryer combos” and “all-in-one washer dryers.”

Many laundry appliances include a cabinet (i.e., an appliance housing) with an opening that is accessed by an appliance door. A drum is positioned in the cabinet and is rotatable with respect to the cabinet. The drum typically has a drum opening, accessed through the appliance door, that provides access to a laundry compartment inside the drum. The appliances also include a blower that directs airflow into the drum.

In a heat pump dryer, the airflow is passed through a heat exchanger including an evaporator and a condenser to be heated and dehumidified before being directed into the drum. In many cases, the heat exchanger includes a boost heater. The boost heater supplies energy to heat the airflow during a warmup phase of the heat exchanger. The boost heater is typically arranged at an outlet of the heat exchanger. Once the heat exchanger is at a desired operating point, the boost heater is turned off.

SUMMARY

This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

A laundry appliance, in accordance with the present disclosure, includes a cabinet. A drum defining a laundry compartment is rotatably supported in the cabinet. A blower fan arranged in the cabinet. The blower fan is configured to generate an airflow. A basement is arranged in the cabinet. The basement includes a basement inlet in fluid communication with the blower fan and a basement outlet in fluid communication with the drum. A heat exchanger system is arranged in the basement. A bypass duct is arranged in the cabinet. The bypass duct includes a bypass inlet in fluid communication with the blower fan and a bypass outlet in fluid communication with the drum, the bypass duct selectively directing the airflow around the heat exchanger system. A control module is configured to selectively fluidically connect the blower fan with the bypass inlet of the bypass duct and fluidically isolate the heat exchanger system from the airflow during a first portion of a drying cycle and fluidically connect the basement inlet with the blower fan to direct the airflow across the heat exchanger system during a second portion of the drying cycle.

A method of operating a heat pump dryer, in accordance with the present disclosure, includes initiating a dryer cycle, activating a blower assembly to create an airflow, activating a heat exchanger system including an evaporator coil and a condenser coil in the heat pump dryer, directing the airflow through a bypass duct around at least the evaporator coil of the heat exchanger system and into a drum of the heat pump dryer during a first portion of a drying cycle, closing the bypass duct, and passing the airflow across the evaporator coil and the condenser coil of the heat exchanger system during a second portion of the dryer cycle.

The present disclosure describes a system that allows a heat exchanger system to come up to operational temperatures without being initially burdened by a humid airflow. Keeping the basement closed during a first portion of a drying cycle allows the process airstream from the laundry compartment to reach a maximum relative humidity level. Introducing the process airflow at a high relative humidity into a heat exchanger that is at operating temperature ensures a better heat exchange between the heat exchanger system and the airflow to enhance drying.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a front perspective view of a laundry appliance including a heat exchanger bypass system, in accordance with the present disclosure;

FIG. 2 is a rear perspective view of the exemplary laundry appliance shown in FIG. 1, in accordance with the present disclosure;

FIG. 3 is a partial cross-sectional side view of the exemplary laundry appliance shown in FIG. 1, in accordance with the present disclosure;

FIG. 4 is a perspective view of the basement arranged in the laundry appliance of FIG. 1 including a boost heater, in accordance with the present disclosure;

FIG. 5 is a cross-sectional side view of the basement illustrating the bypass system in a bypass mode, in accordance with an aspect of the present disclosure;

FIG. 6 is a cross-sectional side view of the basement of FIG. 5 illustrating the bypass system in a heat exchange mode, in accordance with an aspect of the present disclosure;

FIG. 7 is a cross-sectional side view of the basement illustrating the bypass system in a bypass mode, in accordance with another aspect of the present disclosure;

FIG. 8 is a cross-sectional side view of the basement of FIG. 7 illustrating the bypass system in a heat exchange mode, in accordance with an aspect of the present disclosure;

FIG. 9 is a cross-sectional side view of the basement illustrating the bypass system in a bypass mode, in accordance with yet another aspect of the present disclosure;

FIG. 10 is a cross-sectional side view of the basement of FIG. 9 illustrating the bypass system in a heat exchange mode, in accordance with an aspect of the present disclosure;

FIG. 11 is a cross-sectional side view of the basement illustrating the bypass system in a bypass mode, in accordance with still yet another aspect of the present disclosure; and

FIG. 12 is a cross-sectional side view of the basement of FIG. 11 illustrating the bypass system in a heat exchange mode, in accordance with an aspect of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

With reference to FIGS. 1-3, a laundry appliance 50 is illustrated. The laundry appliance 50 is a dryer machine and more specifically, a heat pump dryer machine. The laundry appliance 50 is illustrated as having a front-load configuration, though may alternatively have a top-load configuration.

The laundry appliance 50 includes a cabinet 52 that is rectangular in shape. The cabinet 52 includes a front cabinet wall 54 having a front cabinet opening 56, a rear cabinet wall 58 opposite the front cabinet wall 54, a right cabinet sidewall 60 (FIG. 2), and a left cabinet sidewall 62. Right cabinet sidewall 60 and left cabinet sidewall 62 extend between the front cabinet wall 54 and the rear cabinet wall 58. Cabinet 52 is further shown to include a top cabinet wall 64, and a bottom cabinet wall 66. The front cabinet wall 54, rear cabinet wall 58, right cabinet sidewall 60 and left cabinet sidewall 62, top cabinet wall 64, and bottom cabinet wall 66 cooperate to define a cabinet cavity 68 (FIG. 3) inside the cabinet 52.

In some configurations, the laundry appliance 50 may include a control panel 70 that is attached to the front cabinet wall 54. The control panel 70 may be positioned adjacent to the top cabinet wall 64. The control panel 70 may include a display 72, a speaker 74, a control selector 76, and a control module 78. The display 72 may be used to display information, adjust features or settings of the laundry appliance 50, present prompts to users of the laundry appliance 50, and to perform one or more other functions. The display 72 may be a touch screen display. The speaker 74 may be used to output audible sounds and to perform one or more other functions. The control selector 76 may be used to adjust features or settings of the laundry appliance 50 and to perform one or more other functions.

The control module 78 may receive input from the user (e.g., via the display 72 or the control selector 76). The control module 78 may be configured to operate a cycle (e.g., a drying cycle) of the laundry appliance 50 according to the user's input and may perform one or more other functions. Additional functions of the control module 78 will be described below. It should be appreciated that display 72, speaker 74, control selector 76, and control module 78 may be positioned in another suitable location on the laundry appliance 50.

A front appliance door 84 is pivotally connected to the cabinet 52, and more specifically, to the front cabinet wall 54 of the cabinet 52. The front appliance door 84 swings between an open door position and a closed door position. In the open door position, the front appliance door 84 provides access to the front cabinet opening 56. In the closed door position, the front appliance door 84 shuts or closes the front cabinet opening 56. When in the closed door position, the front appliance door 84 may be flush with or positioned adjacent to a front facia 86 of the cabinet 52. Although other materials can be used, in the illustrated example, the front appliance door 84 is composed of metal.

The laundry appliance 50 includes a drum 90 that is positioned in the cabinet cavity 68 and is rotatable with respect to the cabinet 52 about a drum axis 92. The drum 90 has a cylindrical shape and extends between a front drum end 94 and a rear drum end 96. The drum 90 includes a front drum opening 98 at the front drum end 94, a rear drum wall 100 at the rear drum end 96, and a drum sidewall 102 that extends between the front drum end 94 and rear drum end 96. One or more drum inlets 104 extend through the rear drum wall 100.

The front drum end 94, the drum sidewall 102, and the rear drum wall 100 cooperate to define a laundry compartment 110 inside the drum 90. The front cabinet opening 56 in the front cabinet wall 54 and the front drum opening 98 at the front drum end 94 are at least partially aligned with one another and therefore provide access to the laundry compartment 110 inside the drum 90 when the front appliance door 84 is in the open door position. In the illustrated example, the front cabinet opening 56 in the front cabinet wall 54 and the front drum opening 98 at the front drum end 94 are aligned with the drum axis 92. It should be appreciated that in use, laundry (e.g., clothes, towels, and/or bedding, etc.) is placed inside the laundry compartment 110 where it is dried during the drying cycle of the laundry appliance 50.

Referring to FIG. 4 and with continued reference to FIGS. 1-3, the laundry appliance 50 includes an appliance base 116 disposed between the drum 90 and the bottom cabinet wall 66. The appliance base 116 is attached to the bottom cabinet wall 66. The appliance base 116 extends between a front base end 118 and a rear base end 120 that is opposite the front base end 118. The front base end 118 is positioned adjacent to and attached to the front cabinet wall 54. The rear base end 120 is positioned adjacent to and attached to the rear cabinet wall 58. The appliance base 116 extends laterally between a first base end 122 and a second base end 123 opposite the first base end 122. The first base end 122 is positioned adjacent to the right cabinet sidewall 60 and the second base end 123 is positioned adjacent to the left cabinet sidewall 62.

The laundry appliance 50 includes a heat exchanger system 144 disposed within a basement 146 of the appliance base 116. The heat exchanger system 144 is configured to heat air flowing through the appliance base 116 towards laundry compartment 110. The basement 146 is positioned adjacent to the first base end 122 and between the front base end 118 and rear base end 120 of the appliance base 116. The basement 146 includes a front basement wall 148, a rear basement wall 150, basement sidewalls 152 extending between the front basement wall 148 and rear basement wall 150, and a bottom basement wall 154.

The front basement wall 148 is positioned adjacent to the front base end 118 of the appliance base 116. The rear basement wall 150 is positioned adjacent to the rear base end 120 of the appliance base 116. The basement 146 is arranged in fluid communication with laundry compartment 110 via a first basement opening 156 in the rear basement wall 150. The basement 146 includes a second basement opening 158 (FIG. 5) in the front basement wall 148. Second basement opening 158 defines a basement inlet 160. The bottom basement wall 154 may be inclined such that the bottom basement wall 154 in a position adjacent to the rear basement wall 150 is positioned lower (e.g., closer to the bottom cabinet wall 66) than the bottom basement wall 154 in a position adjacent to the front basement wall 148. In other words, the bottom basement wall 154 in a position adjacent to the front basement wall 148, is positioned higher (e.g., closer to the top cabinet wall 64) than the bottom basement wall 154 in a position adjacent to the rear basement wall 150.

In accordance with an aspect of the present disclosure, heat exchanger system 144 is configured to receive refrigerant or another suitable fluid from a compressor 180. The compressor 180 is attached to the appliance base 116 and is positioned adjacent to the rear base end 120 and the second base end 123. Compressor 180 includes a refrigerant outlet 186 that is in fluid communication with heat exchanger system 144.

Compressor 180 pressurizes the refrigerant flowing through heat exchanger system 144. When compressed, the temperature of the refrigerant increases. The increase in temperature is passed into the airflow passing through heat exchanger system 144 and on into drum 90. More specifically, the airflow, once heated, is passed into laundry compartment 110 to dry articles, for example, articles of clothing, arranged therein.

The appliance base 116 includes an airflow channel 210 disposed adjacent to the basement 146. The airflow channel 210 extends between a first channel end 212 and a second channel end 214 that is opposite the first channel end 212. First channel end 212 defines an airflow outlet 215. A sidewall 216 extends between and connects the first channel end 212 with the second channel end 214 through a bend portion 217.

The first channel end 212, and more specifically, airflow outlet 215, is arranged in fluid communication with the basement 146 via the second basement opening 158, e.g., basement inlet 160. The second channel end 214 is positioned at the front base end 118 the appliance base 116 and adjacent to the second base end 123 of the appliance base 116. As shown in FIG. 2, basement 146 is in fluid communication with drum 90 via a connector channel 218. More specifically, first basement opening 156 is in fluid communication with connector channel 218 which, in turn, is in fluid communication with drum 90 as will be detailed herein.

The connector channel 218 extends between a first connector end 220 and a second connector end 222 that is opposite the first connector end 220. The first connector end 220 is arranged in fluid communication with first basement opening 156. The second connector end 222 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via one or more drum inlets 104 (shown in FIG. 3). The airflow, heated by heat exchanger system 144 travels along a primary flow path “P” and is passed into laundry compartment via drum inlets 104. After interacting with articles in laundry compartment 110, the airflow exits laundry compartment 110 via front drum opening 98 and passes into an airflow outlet 224 of a return duct 226. Return duct 226 may direct air back into heat exchanger system 144 or, in other aspects, may pass the airflow exiting drum 90 to ambient.

A blower 230 (FIG. 4) is configured to blow air through the airflow channel 210, into basement 146, across heat exchanger system 144, and into drum 90. The blower 230 includes a squirrel cage or blower fan 232 arranged at second channel end 214 of airflow channel 210. Blower fan 232 is operatively connected to a motor 234 that is positioned in the appliance base 116. The motor 234 is positioned adjacent to the front base end 118 and the second base end 123 of the appliance base 116.

The motor 234 is positioned between the airflow channel 210 and the compressor 180. In accordance with an exemplary aspect, motor 234 may be a variable speed motor that is operatively connected to control module 78. In accordance with another exemplary aspect, motor 234 may take the form of a variable speed dual rotor motor having a drum motor portion 236 operatively connected to drum 90 and a blower motor portion 238 operatively connected to blower fan 232.

A base cover 244 is sealingly engaged with the appliance base 116 and disposed on top of the appliance base 116. More specifically, the base cover 244 extends over and encloses the basement 146 and the airflow channel 210. The base cover 244 and the basement 146 cooperate to define a basement cavity 246. Blower 230 includes an outlet (not shown) that directs air through airflow channel 210 into basement cavity 246. The air passes in heat exchange relationship with heat exchanger system 144. Heat exchanger system 144 removes moisture from and heats the airflow passing through basement cavity 246. The air is then directed into laundry compartment 110.

In accordance with a non-limiting example, laundry appliance 50 includes a bypass duct 260 arranged on base cover 244. Bypass duct 260 isolates heat exchanger system 144 from air flowing from blower 230 during selected portions of a drying cycle. As shown in FIG. 5, bypass duct 260 includes a bypass inlet 264 arranged vertically upwardly from second basement opening 158, a bypass outlet 266 arranged vertically upwardly relative to first basement opening 156 and a bypass cover 268. During an initial stage of a drying cycle, airflow from blower 230 is guided along a bypass flow path “B” that extends into and through the bypass duct 260 as heat exchanger system 144 comes up to operational temperature.

In a non-limiting example, a door 270 is selectively positionable across second basement opening 158. Door 270 is connected to control module 78. Control module 78 includes a central processing unit (CPU) 280, a non-volatile memory 282, and a door control module 284. Control module 78 is operatively connected to a first sensor 288 arranged in return duct 226 and a second sensor 290 arranged in basement cavity 246. Door control module 284 is operable to shift door 270 between a first position, as shown in FIG. 5 wherein door 270 covers basement inlet 160 isolating heat exchanger system 144 from the airflow generated by blower 230 and a second position, as shown in FIG. 6, wherein door 270 covers bypass inlet 264 allowing the airflow to pass through heat exchanger system 144, be heated, and flow into laundry compartment 110.

Control module 78 moves door 270 to the second position when a drying cycle is initiated. In the second position, airflow generated by blower 230 bypasses basement cavity 246 and flows from the bypass flow path “B” and out into drum 90 via bypass duct 260. Control module 78 may sample air temperature in basement cavity through second sensor 290, and humidity in return duct 226 via second sensor 290. When the temperature and/or the humidity of the airflow reaches a selected threshold, door control module 284 shifts door 270 to the first position covering bypass inlet 264 and exposing basement inlet 160.

In a non-limiting example, door 270 transitions along a guide track 300 having a first portion 304 and a second portion 306. Second portion 306 is substantially perpendicular to first portion 204. Guide track 300 is mounted to or formed in sidewall 216 of airflow channel 210 on either side of basement inlet 160. Door 270 incudes a first end or upper edge 308 including a first roller 310 and a second end or lower edge 312 including a second roller 314. First roller 310 rides in first portion 304 of guide track 300 and second roller 314 rides in second portion 306 of guide track 300. Of course, it should be understood, that door 270 includes additional rollers (not shown) on a side (also not shown) opposite to first roller 310 and second roller 314.

Referring to FIGS. 7 and 8, laundry appliance 50 is shown to include a first door 317 and a second door 320, and guide track 300 includes a third portion 324. In this arrangement, first door 317 includes a first upper roller 326 and a first lower roller 328. First upper roller 326 rides in first portion 304 of guide track 300 and first lower roller 328 rides in second portion 306 of guide track 300. Second door 320 includes a second upper roller 332 and a second lower roller 334. Second lower roller 334 rides in second portion 306 of guide track 300 and second lower roller 334 rides in third portion 324 of guide track 300.

First door 317 and second door 320 may transition between a first position (FIG. 7) wherein bypass inlet 264 is open and basement inlet 160 is blocked, and a second position (FIG. 8) wherein bypass inlet 264 is covered and basement inlet 160 is exposed to the airflow emanating from blower 230. In a manner similar to that discussed herein, first door 317 and second door 320 may isolate basement cavity 246 from blower 230 until heat exchanger system 144 reaches operating temperature.

Referring to FIGS. 9 and 10, laundry appliance 50 is shown to includes a nested door 344 that selectively covers bypass inlet 264. Nested door 344 includes a first door member 346 and a second door member 348. As will become more readily apparent, first door member 346 selectively nests, or is received, within second door member 348. Second door member 348 is received in an opening (not separately labeled) formed in bypass cover 268.

First door member 346 includes a first end 350 and a second end 352. Second end 352 is opposite to first end 350. For example, first end 350 defines a lower end of first door member 346 and second end 352 defines an upper end of first door member 346. A first flange 354 is provided in second end 352 of first door member 346. Second door member 348 includes a first end portion 357 and a second end portion 359 that is opposite to first end portion 357.

Second door member 348 includes a hollow interior 362 and a second flange 364 arranged at second end portion 359. First door member 346 is received in hollow interior 362 and shiftable relative to second door member 348. First flange 354 prevents first door member 346 from passing out of hollow interior 362. Second door member 348 is received in an opening (not separately labeled) formed in base cover 244. Second flange 364 prevents second door member 348 from passing through base cover 244.

In a non-limiting example, an actuator 366 is connected to first door member 346 and control module 78. Actuator 366 includes a spool 370 and a cable 372. Cable 372 is connected to spool 370 and second end 352 of first door member 346. At an initial portion of a drying cycle, first door member 346 and second door member 348 extend across basement inlet 160 (FIG. 9) blocking the airflow though heat exchanger system 144.

When signaled by door control module 284, for example when second sensor 290 detects that a temperature in basement cavity 246 indicates that heat exchanger system 144 has come up to operating temperature, door control signals actuator 366 to rotate spool 370 causing first door member 346 to shift within hollow interior 362 until first flange 354 engages with second flange 364. Further rotation of spool 370 results in first door member 346 lifting second door member 348 through an interaction between first flange 354 and second flange 364 to block bypass inlet 264 and open basement cavity 246 (FIG. 10) to an airflow that will pass through heat exchanger system 144, be heated, and flow into laundry compartment 110.

Reference will now follow to FIGS. 11 and 12 in describing tandem doors 378 that selectively cover and uncover basement inlet 160. Tandem doors 378 include a first door 380 and a second door 382. First door 380 and second door 382 transition along a guide track 384 including a first portion 386, a second portion 388, and a third portion 390. First door 380 includes a first end 400 and a second end 402. Second end 402 is opposite to first end 400. Second door 382 includes a first end portion 404 and a second end portion 406.

Second end portion 406 is opposite to first end portion 404. First end 400 is operatively coupled to first end portion 404 through a linkage member 410. First end 400 includes a first roller 412 and second end 402 includes a second roller 414. Likewise, first end portion 404 of second door 382 includes a third roller 420 and second end portion 406 of second door 382 includes a fourth roller 422. First roller 412 and third roller 420 are disposed in first portion 386 of guide track 384. Second roller 414 is arranged in second portion 388 of guide track 384 and fourth roller 422 is arranged in third portion 390 of guide track 384.

With this arrangement, a force, such as may be generated by actuator 366, applied to first end 400 causes first door 380 and second door 382 to transition between a first position, wherein basement inlet 160 is blocked and bypass inlet 264 is exposed (FIG. 12) and a second position wherein basement inlet 160 is exposed. In the second position, bypass inlet 264 may remain open however a majority of the airflow passes through basement inlet and across heat exchanger system 144. Transition to the second position occurs when heat exchanger system 144 comes up to operating temperature. In the second position, the airflow passes between first door 380 and second door 382 into basement 146, heated by heat exchanger system 144, and passed into laundry compartment 110 to laundry articles contained therein.

At this point, it should be readily apparent that the present disclosure describes a system that allows a heat exchanger system to come up to operational temperatures without being initially burdened by a humid airflow. Further, keeping the basement closed during an initial stage of a drying cycle allows the process airstream from the laundry compartment to reach a maximum relative humidity level. Introducing the process airflow at a high relative humidity into a heat exchanger that is at operating temperature ensures a better heat exchange between the heat exchanger system and the airflow to enhance drying.

When the terms “about” or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value includes a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the terms “generally” or “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Furthermore, regardless of whether numerical values or shapes are modified as “about,” “generally,” or “substantially,” it will be understood that these values and shapes should be construed as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical values or shapes.

Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below”, or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A laundry appliance comprising:

a cabinet;

a drum rotatably supported in the cabinet;

a blower fan arranged in the cabinet, the blower fan being configured to generate an airflow;

a basement arranged in the cabinet, the basement including a basement inlet in fluid communication with the blower fan and a basement outlet in fluid communication with the drum;

a heat exchanger system arranged in the basement along a primary flow path;

a bypass duct arranged in the cabinet, the bypass duct including a bypass inlet in fluid communication with the blower fan and a bypass outlet in fluid communication with the drum, the bypass duct selectively directing the airflow through a bypass flow path around the heat exchanger system; and

a control module configured to selectively fluidically connect the blower fan with the bypass inlet of the bypass duct and fluidically isolate the heat exchanger system from the airflow during a first portion of a drying cycle and fluidically connect the basement inlet with the blower fan to direct the airflow through the primary flow path across the heat exchanger system during a second portion of the drying cycle.

2. The laundry appliance according to claim 1, further comprising a door arranged at the basement inlet, the door being operatively connected to the control module.

3. The laundry appliance according to claim 2, further comprising an airflow channel extending between the blower fan and the basement, the airflow channel including an outlet in selected fluid communication with the inlet of the basement and the bypass inlet.

4. The laundry appliance according to claim 3, further comprising: a guide track arranged along the airflow channel, the door being shiftable along the guide track to selectively connect the blower fan with the bypass duct and the basement.

5. The laundry appliance according to claim 4, wherein the guide track includes a first portion extending along the airflow channel in a first direction and a second portion extending along the airflow channel in a second direction that is substantially perpendicular to the first direction.

6. The laundry appliance according to claim 5, wherein the door includes a first end supporting a first roller and a second end supporting a second roller, the first roller being arranged in the first portion of the guide track and the second roller being arranged in the second portion of the guide track.

7. The laundry appliance according to claim 6, wherein the guide track includes a third portion parallel to the first portion.

8. The laundry appliance according to claim 7, wherein the door includes a first door slidable in the first portion and the second portion of the guide track and a second door slidable in the second portion and the third portion of the guide track.

9. The laundry appliance according to claim 1, wherein the bypass duct extends over the basement.

10. The laundry appliance according to claim 9, wherein the bypass inlet and the basement inlet are substantially vertically aligned.

11. The laundry appliance according to claim 10, further comprising a door operatively connected to the control module, the door being selectively vertically shiftable to close one of the bypass inlet and the basement inlet.

12. The laundry appliance according to claim 11, wherein the door includes a first door member and a second door member, the first door member being operatively connected with the second door member.

13. The laundry appliance according to claim 12, wherein the first door member is selectively nested within the second door member.

14. The laundry appliance according to claim 13, further comprising a door actuator operatively connected to the first door member, the door actuator being selectively activated to shift the first door member and the second door member to open one of the bypass inlet and the basement inlet to the airflow.

15. A method of operating a heat pump dryer comprising:

initiating a dryer cycle;

activating a blower assembly to create an airflow;

activating a heat exchanger system including an evaporator coil and a condenser coil in the heat pump dryer;

directing the airflow through a bypass flow path that bypasses at least the evaporator coil of the heat exchanger system and returns into a drum of the heat pump dryer during a first portion of a drying cycle;

closing the bypass flow path; and

directing the airflow through a primary flow path across the evaporator coil and the condenser coil of the heat exchanger system during a second portion of the dryer cycle.

16. The method of claim 15, wherein directing the airflow through the bypass flow path includes shifting a door across an inlet to the heat exchanger system.

17. The method of claim 16, wherein shifting the door across the inlet of the heat exchanger system exposes a bypass duct to the airflow.

18. The method of claim 16, wherein shifting the door includes sliding a first end of the door along a first portion of a guide track and a second end of the door along a second portion of the guide track that is substantially perpendicular to the first portion of the guide track.

19. The method of claim 18, wherein shifting the door further includes:

sliding a first end of a first door along a first portion of the guide track and a second end of the first door along a second portion of the guide track that is substantially perpendicular to the first portion of the guide track; and

sliding a first end portion of a second door along the first portion of the guide track and a second end portion of the second door along a third portion of the guide track that is substantially parallel to the second portion of the guide track.

20. The method of claim 16, wherein shifting the door further includes raising a first door member linked to a second door member and shifting the first door member and the second door member to close the bypass flow path and expose the heat exchanger system to the airflow.